Materials Science Forum Vols. 768-769

Abstract: The present investigation was carried out in order to determine residual stresses inNi-based self-fluxing alloy based high velocity oxy-fuel (HVOF) coatings with different wearresistant additives. The main components of the alloy were Ni, Cr, Si and B. To increase the wearresistance of self-fluxing NiCrSiB alloy based coatings, different ceramics and hard metals(WC-Co, TiC-NiMo and Cr2C3-Ni) were added. Residual stresses were measured by the holedrillingmethod and the X-ray method. The incremental hole-drilling technique combined with theintegral method was applied. This combined method allows to analyse non-uniform throughthicknessresidual stresses. The results obtained with the incremental hole-drilling method indicatethat through-thickness residual stress distribution is non-uniform. The determined residual stresseswere tensile on the surface of the coating and became compressive toward the interface.The values of the modulus of elasticity and microhardness of the coatings were obtained byinstrumented indentation. The microstructures of the studied coatings were investigated with theSEM technique.

Abstract: This paper shows a large validation activity of the strain gage Hole Drilling Method. The residual stress measurements can not be validated easily, unless with Round Robin activity and/or comparison with other residual stress measurements such as X-ray diffraction. An accurate validation procedure is reported in the present paper, using abending test rig. The bending stress experimentally simulated a residual stress (known with uncertainty lower than 1%) that was considered as the reference stress distribution. The results showed very accurate measurement in terms of relaxed strain distributions, that were compared with the prediction obtained with the Influence Function technique. The differences were in the order of 0.5 microepsilon as standard deviation on a large number of tests. The bending stress prediction was consequently very accurate and the stress differences were as small as 1 MPa showing the accuracy potentiality of the method.

Abstract: Highly stressed machine parts such as gears and shafts are often surface treated to increase wear and fatigue resistance at critical locations. For example, induction surface hardening (ISH) is increasingly used in the automotive and aerospace industries thanks to the availability of modern multiple frequencies generators and complex shaped coils that provide a great flexibility in process control. With similar end-results in terms of hardened depths, very different residual stress profiles may be obtained, and optimized by modifying both heating and quenching kinetics. If hardness and microstructures variations are routinely verified, some challenges raise for the measurement of the residual stress gradients within complex geometry parts, in particular for the case of deep hardened layers. The most commonly used technique is X-ray diffraction (XRD). It requires using successive layer removal to get access to in-depth stresses. The measurements must therefore be corrected for the stress redistribution occurring during layer removal. However, industrial geometries are often not covered by traditional correction methods. The present work aims at applying XRD to precisely measure in-depth residual stress profiles in induction hardened thin discs made of martensitic steel. Both issues of microstructural variations and redistribution of stresses during layer removal are tackled. First, X-ray elastic constants were determined experimentally using a miniature custom-made tensile machine with specimens heat treated to simulate different microstructures found in ISH parts. Second, a recently introduced finite elements based layer removal correction method was applied. The proposed methodology is used to show the impact of preheating and core hardness on the residual stresses obtained after induction hardening.

Abstract: The technology and equipment for determination of residual stresses in the welded structures, using electron speckle-interferometry combined with the hole-drilling method (ESPI-HD), have been described. A special new approach to the conventional method of speckle-interferometry to investigate the stress gradients over the test object surface has been added. The developed equipment has been applied for determination of residual stresses in the different structures: the gas-turbine rotor, the welded shell and the structural elements with the large grain size.

Abstract: Two commonly used mechanical methods for the determination of residual stresses are the hole-drilling method and the ring-core method, which can be regarded as semi-destructive. The most restricting limitation for the general applicability of both methods, according to the current state of science and technology, is the fact that the scope for relatively low residual stress under 60% of the yield stress is limited.This is a result of the notch effect of the hole or ring core, which leads to a plastification around and on the bottom of the hole and ring shaped groove already at stresses well below the yield stress of the material. The elastic evaluation of the resulting plastic strains leads consequently to an overestimation of the delineated residual stresses. In this paper the influence of elastic-plastic material properties no the specific calibration function for the hole-drilling method using the differential method is studied, and the method of adaptive calibration functions is presented.

Abstract: Residual stresses play a fundamental role in mechanical engineering. They can be generated by manufacturing processes or introduced purposely by surface treatment technologies. One of the most recent technologies developed to introduce residual stresses is Laser Shock Peening. Since it is a relatively expensive technology, a fundamental role is played by the Finite Element Analysis approach to predict the final residual stress profile. The FEA approach consists of either direct simulation of the LSP process or the application of the eigenstrain approach. The application of the eigenstrain theory in predicting residual stresses after LSP treatment in curved edges is the subject of this research.

Abstract: Problems of residual stress analysis can be formulated in terms of so-called eigenstrain or inelastic strain. Although the concept is almost 100 year old, the use of it by the residual stress community is quite limited, due to complexities of the associated mathematics. When mathematical difficulties are resolved and eigenstrain is reconstructed, the use of it can be beneficial in several ways. Firstly, the eigenstrain is essentially a generator function for residual elastic stress and elastic strain and it can be used, for generation of any stress field in FE models. Furthermore, eigenstrain distributions are frequently localized, even though the elastic stress or strain distributions are not. Both these properties can be used for effective data reduction. Another advantage of the use of the eigenstrain concept is that experimental data may be interpreted in a more meaningful way by using a narrower context, in terms of plastic deformation, thermal expansion/misfit and deformation caused by phase transformation, rather than just residual stress/strain field. The sample geometry and symmetry play an important role in resolving eigenstrain distributions from residual stress and elastic strain fields. Generally the equations are difficult to solve, however for a sample geometry of high symmetry, eigenstrain can be resolved and expressed as a solution of a relatively simple integral equation; which is the Fredholm of the second type with the kernel of the integral operator defined by the sample geometry/symmetry. Several such symmetries are investigated, yielding analytical solutions that are applied and contrasted to experimental data. An important issue for residual stress analysis is the uniqueness of the solution is also discussed.

Abstract: Aero-engine components exposed to high mechanical stresses are made of high-strength alloys and additionally, they are surface treated by shot peening. This process introduces compressive residual stress into the material making it less sensitive to stress corrosion cracking and fatigue and therefore benefits the components performance and lifetime. Moreover cold work is induced in an amount depending on the peening parameters. To approximate the remaining lifetime, a quantitative, non-destructive method for stress assessment is required. It was shown that surface treatment of such alloys can be characterized by broadband Rayleigh wave dispersion measurements. However, the relative contributions of residual stress and cold work, respectively, remained an open point. This paper presents the determination of third order elastic constants (TOEC) for IN718 and Ti6246, providing, together with a model for the inversion of dispersion data, a quantitative access to the acoustoelastic effect. Finally, some measurements of differently treated samples are given.

Abstract: A nonlinear empirical model between stress and Barkhausen noise is identified in this study. The identification procedure uses a genetic algorithm followed by a Nelder-Mead optimization procedure. The model is identified with the data set where an external load is applied to RAEX400 low alloyed hot-rolled steel samples. The results of the study show that the identified model performs well in stress predictions. The identified model includes three terms which are in accordance with the literature.

Abstract: Efficient manufacturing requires consistency. Automated equipment is designed to accept a small range of input variability and quickly sort and process for next steps. A case study for injection molding of polyethylene terephthalate preforms for use in stretch-blow molding was presented. One convenient method for measuring stresses in optically transparent birefringent parts is photoelasticity. Using cross-polarized light, fringes proportional to the stress state were observed. Faster cooling improved the residual stress state in the injected preforms. The improvements were both in magnitude, as represented by the frequency of fringes and consistency, as represented by the improved symmetry of the fringes. Lower pressure in the mold also aided in improving the residual stress state. Reducing the pressure needed to inject was accomplished by increasing the vent width.